Pile for tower foundation

Abstract

Disclosed herein is a foundation pile. The foundation pile comprises a first flange. The foundation pile also comprises a second flange spaced apart from the first flange. The foundation pile further comprises a web extending between the first flange and the second flange, wherein the first flange, the second flange, and the web are formed from a single sheet and each comprises at least two layers of the sheet. The foundation pile additionally comprises a rib formed in at least one of the first flange, the second flange, and the web, wherein the rib comprises a bent portion of at least one of the at least two layers of the sheet.

What is claimed is: 
     
       1. A foundation pile, comprising:
 a first flange; 
 a second flange spaced apart from the first flange; 
 a web extending between the first flange and the second flange, wherein the first flange, the second flange, and the web are formed from a single sheet and each comprises at least two layers of the sheet; and 
 at least one rib formed in each one of the first flange and the second flange, wherein the rib comprises a bent portion of at least one of the at least two layers of the sheet; 
 wherein:
 each one of the first flange and the second flange has a first length; 
 the at least one rib formed in each one of the first flange and the second flange has a second length; and 
 the second length is less than the first length. 
 
 
     
     
       2. The foundation pile according to  claim 1 , wherein:
 the foundation pile has a first length; 
 the rib has a second length; and 
 the second length is equal to the first length. 
 
     
     
       3. The foundation pile according to  claim 1 , wherein:
 the rib comprises opposing ends; and 
 each of the opposing ends is tapered. 
 
     
     
       4. The foundation pile according to  claim 1 , wherein the rib comprises bent portions of two layers of the at least two layers of the sheet. 
     
     
       5. The foundation pile according to  claim 4 , wherein the bent portions of the rib abut each other. 
     
     
       6. The foundation pile according to  claim 1 , wherein the bent portion of the rib is bent, relative to an adjacent layer of the at least two layers, such that an open pocket is defined between the bent portion and the adjacent layer. 
     
     
       7. The foundation pile according to  claim 1 , wherein the rib has a triangular cross-sectional shape. 
     
     
       8. The foundation pile according to  claim 1 , wherein the rib has a trapezoidal cross-sectional shape. 
     
     
       9. The foundation pile according to  claim 1 , wherein the rib has a rectangular cross-sectional shape. 
     
     
       10. The foundation pile according to  claim 1 , wherein the rib is elongated in a direction parallel to a length of the foundation pile. 
     
     
       11. The foundation pile according to  claim 1 , wherein:
 multiple ribs are formed in the first flange; and 
 multiple ribs are formed in the second flange. 
 
     
     
       12. The foundation pile according to  claim 11 , wherein:
 the multiple ribs formed in the first flange are elongated in a direction parallel to a length of the foundation pile and spaced apart from each other in a direction parallel to a width of the foundation pile; and 
 the multiple ribs formed in the second flange are elongated in a direction parallel to a length of the foundation pile and spaced apart from each other in a direction parallel to a width of the foundation pile. 
 
     
     
       13. The foundation pile according to  claim 1 , wherein:
 the at least one rib formed in the first flange projects away from the second flange; and 
 the at least one rib formed in the second flange projects away from the first flange. 
 
     
     
       14. The foundation pile according to  claim 1 , wherein:
 the at least one rib formed in the first flange projects toward the second flange; and 
 the at least one rib formed in the second flange projects toward the first flange. 
 
     
     
       15. The foundation pile according to  claim 1 , wherein at least one rib is formed in the web. 
     
     
       16. The foundation pile according to  claim 1 , wherein the single sheet is continuous and seamless. 
     
     
       17. The foundation pile according to  claim 1 , wherein the foundation pile is free of a bonding agent between the at least two layers of the sheet. 
     
     
       18. The foundation pile according to  claim 1 , wherein:
 the at least one rib formed in the first flange extends along a middle of the first flange such that a plane parallel to and intersecting the web extends through the at least one rib formed in the first flange; and 
 the at least one rib formed in the second flange extends along a middle of the second flange such that the plane parallel to and intersecting the web extends through the at least one rib formed in the second flange. 
 
     
     
       19. The foundation pile according to  claim 18 , wherein:
 multiple ribs are formed in the first flange; 
 a second one of the multiple ribs formed in the first flange is offset from the middle of the first flange and the plane parallel to and intersecting the web; 
 multiple ribs are formed in the second flange; and 
 a second one of the multiple ribs formed in the second flange is offset from the middle of the second flange and the plane parallel to and intersecting the web. 
 
     
     
       20. The foundation pile according to  claim 19 , wherein:
 a third one of the multiple ribs formed in the first flange is offset from the middle of the first flange and the plane parallel to and intersecting the web, on an opposite side of the middle of the first flange and the plane than the second one of the multiple ribs formed in the first flange; and 
 a third one of the multiple ribs formed in the second flange is offset from the middle of the second flange and the plane parallel to and intersecting the web, on an opposite side of the middle of the second flange and the plane than the second one of the multiple ribs formed in the second flange.